Electric control circuit



Feb. 1, 1944. e. ROGERS ELECTRIC CONTROL CIRCUIT Filed Nov. 19,1942

Attof'neg.

Inventor. George L. R0 era; by 63) Hi gvs QE kwikuwm Q Patented Feb. 1, 1944 ELECTRIC CONTROL CIRCUIT George L. Rogers, Schenectady, N. Y., assignor to General Electric Company, a corporation of New York Application November 19, 1942, Serial No. 466,125

11 Claims. icl. 219-4) My invention relates to improved electric control circuits and more particularly to improved electric valve control circuits for timing a plurality of operations. My invention is particularly adapted'for coordinating the supply of current and application of pressure to the electrodes of a resistance welding machine.

In industrial applications, it is often desirable to time accurately the initiation of a plurality of operations with respect to one another. In some applications, the interval between two operations to be initiated is very short and, in some cases, is shorter than the time required for completing one of the operations. For example, in resistance welding, it has been found desirable to apply a pressure of greater magnitude during the latter part of the period of weld current or shortly proper work-engaging position and the proper application oi. welding pressure to the welding electrodes. One of the timers controls the conduction of the electric valve in the discharge circuit of the capacitor and the other timing circuit controls the energization of the solenoid valve to thereafter to accomplish a forging function.

Where the welding current is of short duration, such as, for example, in capacitor discharge welders, the time required for increasing the pressure,

which usually involves the operation .of solenoid valves or the like, is longer than the total inter val between the initiation of welding current and theiristant at which the increase in pressure is desired. In accordance with the teachings of my invention, 1 provide a new and improved electric control circuit for timing a plurality of operations and which is particularly adapted for coordlnat-- ing the current and pressure cycles of aresistance welding machine.

It is an object of my invention to provide a new and improved electric control circuit.

It is another object of my invention to provide a new and improved electric valve timing circuit.

It is another object of my invention to provide a new and improved electric control circuit for coordinating the initiation of a plurality of operthe electric valve and the operation of the sole-' noid valve is coordinated by an improved electric valve timing circuit which includes an electric valve for initiating the operation of two timing circuits in response to the closure of an initiating switch and the movement of the electrodes into eflect a change in the pressure applied to the welding electrodes. The timing circuits are energl'zed from a direct-current voltage and are synchronized with an altemating-current supply circuit from which the solenoid valve is energized so that the solenoid valve is always energized at the same time in the altemating-current voltage wave. This renders the time of operation of the solenoid valve uniform and permits an accurate timing of the pressure cycle controlled by the valve with respect to the welding current by adjustment of the two timing circuits.

My invention will be better understood by ref erence to the following description taken in connection with the accompanying drawing and its scope will be pointed out in the appended claims. In the drawing, the single figure is a schematic representation of one embodiment of my invention.

Referring now to the drawing, I have shown my invention embodied in a capacitor discharge welding system including a welding transformer I 0 having a secondary winding ll, connected to energize the electrodes l2 and [3 of a welding machine, and a primary winding l4 connected to be energized by the discharge of a capacitance l5 invention of Louis G, Levoy, Jr., as disclosed and claimed in application S. N. 384,247, filed March 20, 1941, and my prior invention as disclosed and claimed in my application S. N. 404,853, filed July 31, 1941. Both of the above applications are assigned to the assignee of the present invention. The initiation of discharge of capacitance I5 and the resulting energization of the welding transformer I0 is controlled by an electric valve 20, preferably of the gaseous-discharge type, having the anode-cathode circuit thereof connected between the anode and the control member I! of 55 the. electric valve I6; The electric valve 20 is provided with a control member or grid 2| and is normally maintained nonconducting by a source of negative-biasing potential supplied by a battery '22." The-electric valve is rendered conductive by means of a voltage impulse impressed on the control member 2| thereof by the secondary winding 23 of a transformer 24 having the primary winding 25 thereof energized at a definite time under the control of my improved timer circuit as will be described more in detail at a later point in the specification.

In the interest of simplification, the welding machine with the exception of the electrodes |2 and I3 and a pressure cylinder 26 and operating piston 21 for the'electrode 3 has been omitted from the drawing. Fluid pressure for moving electrode 3 into work-engaging position is supplied, from a source (not shown), by a conduit 28 under the control of a solenoid valve 29 having an operating coil 30. As a means for increasing the pressure applied to the work by the welding electrode I3, I provide an exhaust conduit 3| communicating with the lower side of piston 21 and which is controlled by a solenoid valve 32 having an operating coil 33 which is energized at an accurately timed instant with respect to the initiation of conductionof the electric valve l8 and the resulting energization of the welding transformer.

,As a source of voltage for the timing circuits for controlling the energization of transformer 24 and solenoid valve 29, I provide a three-wire direct-currentsupply circuit comprising conductors 34, 35, and 38 which are energized from further increase the accuracy of the control, I

connect a resistor 45 and a constant voltage device 48, such as a cold cathode gaseous discharge device, in series across conductors 34 and 35 and is charged from the regulated supply comprising conductors 49 and 59 through an electric discharge device 85. The anode-cathode circuit of the discharge device 85 is connected from conductor 49 through a normally open contact 68 of the relay 51, voltage-dividing resistors 81 and '68, and the operating coil89 of an electromagnetic relay 10. The capacitor 84 is connected between the conductor 50 and an adjustable tap 1| on the resistor 81 through a resistor 12. It is apparent that, when relay 51 is energized, the anode-cathode circuit of electric valves 5| and 65 are complete and, when electric valve 85 is rendered conducting, the capacitor 64 is charged from the voltage appearing between conductors 49 and 50 at a rate dependent upon the magnitude of the capacitor 64, resistor 12, and the setting of the adjustable tap 1| on resistor 61. The com trol member 13 of electric valve 65 is normally a resistor 41 and a constant voltage device 48 across the conductors 35 and 38. 49 connected to the common terminal of resistor 45 and constant voltage device 48 and a. conductor 50 connected to the common terminal of the resistor 41 and constant voltage device 48 provide a source of regulated direct-current voltage.

As previously mentioned, the initiation of discharge of capacitor |5 and, as a result, energization. of the welding transformer is accomplished by supplying an impulse of voltage to the primary winding 25. This is accomplished by controlling the conductivity of an electric discharge device 5| of the type utilizing an ionizable medium and including an anode 52, a cathode 53, a control member or grid 54, and a shield grid which is connected directly to the cathode. The anode-cathode circuit of the electric valve 5| is completed from the direct-current supply conductor 34 to the conductor 35 through the normally open contact 58 of arelay 51, a resistor 58 and a parallel capacitor 59, a resistor 80, the primary winding 25 of the transformer 24, and the operating coil 8| of a relay 82. The control member 54 of the electric valve 5| is connected through a current-limiting resistor' 83 to the positive terminal of a capacitor 84 which A conductor maintained at a negative voltage with respect to the conductor 50 by means of the voltage appearing across the resistor 41. As illustrated in the drawing, control member 13 is connected through a current-limiting resistor 14, the secondary winding 15 of a peaking transformer 16, conductor 11, resistor 18, and resistor 41 to the conductor 50. The primary winding 19 of transformer 18 is connected through a resistor to the alternating-current control voltage supply 31. A loading resistor 8| and capacitor 82 are connected across the secondary of thetransformer 18 to improve the peaking characteristic of the transformer. The conductor 11, which is connected to the control member 13 of electric valve 85, is also connected to conductor 50 through a resistor 83, conductor 84, the normally open contact of a switch illustrated diagrammatically at 88, and conductor 81. The switch 88 is operatively associated with the cylinder 28 of the welding machine and is arranged to close its contact 85 upon the attainment of a predetermined pressure in the cylinder 28 or, as an alternative, in accordance with the pressure and position of the welding electrode |3. It will be apparent from an inspection of the drawing that, with the contact 85 closed, the resistors 18 and 83 are connected across the resistor 41 and, by virtue of the connection of conductor 11 with the common terminal of these resistors, the negative bias on the control member 13 of valve 85 is reduced. The reduction is insuificient, however,

to render the electric valve 85 conducting until the first positive impulse is produced in the transformer secondary winding 15. In this way, initiation of conduction of electric valve 85 is synchronized with the voltage of the alternatingcurrent circuit 31.

When electric valve 85 is rendered conducting, a charging circuit is also established for a 011- 'pacitor 88. From the drawing, it will be noted that the cathode of the electric valve 65 is connected to the conductor 59 of the direct-current supply through voltage-dividing resistors 89 and 98 which are connected in parallel with resistors 81 and 88 andthe coil of relay 10. The positive terminal of the capacitor 88 is connected with an adjustable tap 9| on the resistor 89 through the fixed resistor 92 and an adjustable tapped resistor 93. The voltage of capacitor 88 controls the energization of the operating coil 33 of the solenoid valve 32 by controlling initiation of conduction of an electric discharge valve 94 which is the leading valve of a pair of reversely connected electric valves 94 and 95 which are energized from the alternating-current supply circuit 31 through atransformer 95. The operating coil 33 of the solenoid valve 32 is connected in series with the reversely connected valve 94 and 95 across the secondary windingof the transformer 96. As illustrated in the drawing, the cathode of electric valve 94 is connected with the conductor 35 of the direct-current supply circuit and is preferably grounded as indicated at 91. The control member 98 of electric valve 94 is connected with the positive terminal of capacitor 88 through a current-limiting resistor 99. The trailing electric valve 95 is provided with a control member I which is normally maintained ata negative voltage by means of a self-biasing circuit including a parallel connected capacitor IN and resistor I02 and a hold-off component of alternating-current voltage which is impressed on the control member I00 by a secondary winding of a transformer I03 having,the primary winding thereof energized from the secondary a turn-on voltage on the control member in re- 1 sponse to energization of the coil 32.

Inordento provide for the rapid discharge of capacitors 64 and 88 which control the electric valves BI and 94, respectively, I provide an electric discharge device I01 which is provided with two discharge paths, one of which is connected between the cathode of electric valve 65 and the positive terminal of capacitor 64 and the other of which is connected between the cathode of electric valve 65 and the positive terminal of the capacitor 88: From an inspection ofthe drawing, it will be seen that thi device removes the resistor I2 from the discharge circuits of capacconducting.

itor 64 andthe resistors 92 and 93' from the discharge circuits of capacitor 08 and, in this way, insures the relative rapid discharge of these capacitors when electric valve 65 is rendered non- The operating coil of the relay 5! is connected Levoy, Jr., S. N. 384,247, filed March 20, 1941,

and my application S. N. 404,853, filed July 31, 1943.

A brief description of the operation of the illustrated embodiment of my invention will bring out more clearly the features and advantages of my present invention. Let it be assumed that all of the electric valves have the cathodes thereof at operating temperature and that the controlled rectifier I9 has operated to charge the capacitor I5 to a predetermined value. If, now,

it is desired to make a weld, switches I08 and I09 are closed, operating relay 51 to closed position to complete the anode-cathode circuits of electric valves 5| and 65 and energizing the operating coil 30 of the solenoid valve 29 to close the movable electrode I3 on the work to be welded. When certain mechanical conditions regarding electrode pressure and position are attained, as determined by the switch 86, contact 85 is closed to reduce the negative or hold-01f voltage on resistor 83 of electric valve 61 by an amount dependent upon the relative magnitudes of resistors 12 and 83. These resistors are so chosen that the reduction bias is not suflicient to render the electric valve 05 conducting. However, at the next positive voltage peak impressed on the control member 13 by the secondary winding 15 of transformer 16, electric valve means 65 conducts and the charging of timing capacitors 64 and 88 is initiated simultaneously. The charging rate of capacitor 64 is determined by the magnitude of resistor 12 and the position of the slider II on resistor 01. The charging rate of capacitor 89 is determined by the magnitude of resistor 92, tapped resistor 93, and the position of the taps 9| on resistor 89. The taps on resistor 93 are spaced at increments of resistance which are suflicient to change the time required for capacitor 08 to charge to a predetermined value in increments of one cycle of the alternating-current circuit 31. By choosing the time at which capacitor 88 charges sufficiently to render electric valve 94 conductive so that it fall within the negative half cycle of anode-cathode voltage of the valve 94, it is apparent that the valve will start to conduct at the beginning of the next half cycle of voltage. In this way, any variation in the charging of capacitor 88 within a halfcycle range will not change the time at which electric valve 94 is rendered conductive and, as a result, the operating coil 33 of the solenoid valve 32 is always energized at the same'time in the alternating-current voltage wave. This is important in a circuit where precision timing is desired inasmuch as variations in the operating time of thesolenoid are substantially eliminated. When the capacitor 64 charges to a predetermined value, the control member 54 of the valve Si is made more positive than the conductor to which the cathode of the valve 5| is connectedand valve 5I is rendered conductive. The initial impulse of current through valve 5|, the capacitor .59, and the primary winding 25 of transformer 24 induces a voltage in the winding 23 which renders firing valve 20 conductive. This renders electric valve I6 conductive and initiates. the discharge of capacitor I5 through the welding transformer primary winding I4.

Summarizing the operation briefly, conduction of the valve establishes a reference time which is synchronized with the alternating-current supply voltage of circuit 31. At independently adjustable times after this reference, electric valves 5I-and 94 are rendered conductive to initiate the current cycle and an increase in pressure applied to the welding electrodes, respectively. .Inasmuch as the energization of the welding transformer is substantially instantaneous and the increase in pressure on the electrodes may require a cycle or so to accomplish. it is sometimes necessary to adjust the timing circuit including capacitor 88 to render electric valve 94 conductive prior to the time electric valve 5| is rendered conductive even though the increased pressure is to be applied only after the completion of the welding current impulse. In the operation of the illustrated embodiment of the invention, adjustments in the timing of the current impulsewith respect tothe increase in electrode pressure may be made in one-cycle steps by means of the adjustable tap on resistor 93 and fractions of a cycle variation accomplished by adjusting the timing circuit including electric valve 5| and capacitor 64. In this way, the latter timing circuit is required to operate over a range which varies very little and, as a result, itmay be made to operate very precisely. As previously pointed out, synchronizing the timing energization of the operating coil 33 of the solenoid valve 32 renders the operating time of the valve substantially constant and makes itpossible to take account of this operating time when adjusting the charging circuits of capacitors G4 and 88.

In the description of the illustrated embodiment of the invention, relays B2 and were described as having the operating coils thereof connected in circuit with the electric valves 5| and 55. respectively. These relays are not essential to the operation of the illustrated embodiment of the invention and may be employed for initiating any controlling function which it is desired to effect upon the initiation of conduction of elec-. tric valves 5! and 65, respectively.

While I have shown and described a particular embodiment of my invention, it will be obvious to those skilled in the art that changes and modi fications may be made without departing from my invention in its broader aspects, and I, therefore, aim in the appended claims to cover all such changes and modifications as fall within the tru spirit and scope of my invention.

What I claim as new and desire to secure by Letters Patent of the United States is:

1. In combination, a welding circuit including welding electrodes, means including an electromagnetic device for controlling the pressure ex-.

mentioned electric valve conductive when the I charge on. said one capacitor reaches a predetermined value to initiate energization of said weld-- ing electrodes, and means responsive to the voltage of the other of said capacitors for rendering said second electric valve conductive to energize said electromagnetic device and effect a change in the pressure exerted on the work at an accurately predetermined timed instant with respect to the initiation of energization of said ously and in synchronous relation with the voltage of said alternating-current circuit when said electrodes are exerting a predetermined pressure on the work, means for independently adjusting the charging rates of said capacitors, means responsive to the voltage on one of said capacitors for rendering said first-mentioned electric valve conductive when the charge on said one capacitor reaches a predetermined value to initiate energization of said welding electrodes, and means responsive to-the voltage of the other of said capacitors for rendering said second electric valve conductive to energize said electromagnetic device and effect an increase in the pressure exerted on the work at an accurately predetermined timed instant with respect to the initiation of energization of said welding electrodes.

3. In combination, a welding circuit including welding electrodes, means including an electro magnetic device for controlling the pressure exerted on work received between said electrodes, means including an electric valve for controlling the energization of said welding electrodes, an alternating-current circuit, means including a second electric valve for controlling energization of said electromagnetic device from said alternating-current circuit, a pair of timers, a third elec tric valve, means for rendering said third electric valve conductive in synchronim with said alternating-current circuit and only after said electrodes have been moved into work-engaging position and are exerting a predetermined pressure thereon, means for independently adjusting the periods or operation of said ti'mers, means responsive to operation of one of said timers for controlling said first-mentioned electric valve to initiate energization of said electrodes, andmeans responsive to operation of the other 01' said timing devices for energizing said electromagnetic device to increase the pressure. exerted on the work at an accurately predetermined timed instant with respect to the energization of said welding electrodes.

4. In combination, a welding circuit including welding electrodes, means including an electromagnetic device for controlling the pressure exerted on work received between said electrodes, means including an electric valve for controlling the energization of said welding electrodes, an alternating-current circuit, means including a second electric valve for controlling energization of said electromagnetic device from said alternating-current circuit, a Pair of timers, a third electric valve, means for rendering said third electric valve conductive in synchronism with said alternating-current circuit to establish a reference time, means for independently adjusting the period of operation of said timers, means responsive to operation of one of said timers for controlling said first-mentioned electric valve to initiate energization of said electrodes, and means responsive to operation of the other of said timingdevices for energizing said electromagnetic device to increase the pressure exerted on the Work at an accurately predetermined timed instant with respect to the energization of said welding electrodes.

5. In combination, a welding circuit including welding electrodes, means including an electric valve for controlling the energization of said welding electrodes, means for operating said electrodes into work-engaging position and for exerting a predetermined working pressure on said electrodes, an alternating-current circuit, means including an electromagnetic device connected to be energized from said alternating-current circuit for effecting a change in the pressure exerted on said, electrodes, a source of unidirectional voltage, a pair of capacitors, a second electric valve, and a pair of independently adjustable charging circuits connecting said cacircuit, means responsive to the voltage of the other of said capacitors for rendering said firstmentioned electric valve conductive to initiate energization of said electrodes so that the energization of said electrodes and-the change in pressure exerted on said electrodes occur at predetermined times after said reference time.

6. In combination, a welding circuit including welding electrodes, means including an electric valve for controlling the energization of said welding electrodes, means for operating said electrodes into work-engaging position and for exerting a predetermined working pressure on said electrodes, an alternating-current circuit, means including an electromagnetic device connected to be energized from said altematingcurrent circuit for effecting a change in the pressure exerted on said electrodes, a source of unidirectional voltage, a pair of capacitors, a second electric valve,and a-pair of independently adjustable charging circuits connecting said capacitors with said source of unidirectional voltage through said second electric valve, means for rendering said second electric valve conducting in synchronism with saidalternating-current circuit to initiate simultaneously the charging of both of said capacitors and to establish a reference time, means for adjusting one of said charging circuits in steps which alter the time required for the associated capacitor to charge to a predetermined value in steps corresponding to integral cycles of said altematingelectric valve and a pair of capacitors connected in series and across said voltage supply so that acharging circuit is established for both said capacitors through said valve when said valve is rendered conducting, means for rendering said second electric valve conducting to establish a reference time, means responsive to the voltage of one of said capacitors for controlling said electromagnetic device, and means responsive to the voltage of the other of said capacitors for controlling said first-mentioned electric valve to ef-,

feet the energization of said electrodes and the modification of the pressure exerted thereon at accurately predetermined timed instants with respect to said reference time.

8. In combination, an altern'ating-currentcircult, a welding circuit including welding electrodes, means including an electric valve for transmitting to said electrodes an impulse of current of short duration with respect to the period of said alternating-current circuit, means for moving said electrodes into work-engagingposition and for exerting a welding pressure on said electrodes, means including an electromagnetic device energized from said alte'mating-current circuit and requiring a long period to operate as compared with said impulse of current for modifying the pressure exerted on said electrodes in timed relation with respect to said impulse of current, means for determining the instants at which said electrodes are energized and said pressure is modified comprising a voltage supply, a second electric valve, and a pair of parallel connected capacitors connected in series and across said voltage supply so. that a charging circuit is established for both said capacitors through said valve when said valve is rendered conducting, means for rendering said second electric valve conducting in synchronism with said alternating-current circuit tov establish a reference time, means responsive to the voltage of one of said capacitors for controlling said electromagnetic device, and means responsive to the voltthe energization of said electrodes and the modicurrent circuit, means responsive to the voltage of said one capacitor for. controlling the energization of said electromagnetic device to energize said device in synchronism with said alternating-current circuit, means responsivetto'the. voltage of the other of said capacitors for ren-.

dering said first-mentioned electric valve conductive to initiate energization of said electrodes so that the energization ,of 'said electrodes and the change in pressure exerted on said electrodes occur at predetermined times after said reference time. I

7.. In combination, an altemating-current circuit, a welding circuit including welding electrodes, means including an electric valve for transmitting to said electrodes an impulse of current 01' short duration with respect to the period of said alternating-current circuit, means for moving said electrodes into work-engaging position and for exerting a welding pressure'on said electrodes, means including an electromagnetic device requiring a long period to operate as com pared with said impulse current for modifying the pressure exerted on said electrodes in timed relation with respect to said impulse of current,

means for determining the instants at which said electrodes are energized and said pressure is modified comprising a voltage supply, a second ilcation of the pressure exerted thereon at accurately predetermined timed instants with respect to said reference time.

9. In combination, an alternating-current circuit,- a direct-current supply circuit, an electric valve and a pair of capacitors connected to said direct-current circuit so that a charging circuit is established for each of said capacitors when said electric valve is rendered conductive, a resistance connected in the charging circuit of one of said capacitors and adjustable in steps which vary the time required for charging said one capacitor to a predetermined value in increments of integral cycles of said altemating-current circuit, and an adjustable resistance in the charging circuit of the other of said capacitors to vary the time required for said other capacitor to charge to a predetermined value in increments which are small compared with a cycle-of said alternatingcurrent circuit, and means responsive to the charge of said capacitors for initiating different operations at. accurately displaced intervals of time.

10. In combination, a source of direct current, an electric valve and a resistance element connected in series across said source of direct ourrent, a capacitor and a resistance element connected in series and across at least a portion of the first-mentioned resistance element so that the capacitor is charged through a circuit including said electric valve and said last-mentioned resistance element when said valve is conducting, and an uncontrolled electric valve shunting at least a portion of the resistance in series with said capacitor and poled to discharge said capacitor when said first-mentioned electric valve is nonconducting.

11. In combination, a source of direct current. an electric valve and a resistance element connected in series across said source of direct current, a pair of capacitors connected to be charged in parallel from said source of direct current through said electric valve, adjustable impedance means in the charging circuits of each of said capacitors, and a pair of unilaterally conducting paths connected between the charging circuits of said capacitors and the anode-cathode circuit of said electric valve to shunt at least a portion of the impedance in the charging circuits of said capacitors and poled to conduct when said electric valve is nonconducting to establish discharge circuits for said capacitors excluding a substantial portion of the impedance in the charging circuits thereof.

GEORGE L. ROGERS. 

